CN108656673A - 多层复合中空夹芯结构材料及其制备方法 - Google Patents
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Abstract
本发明公开了一种多层复合中空夹芯结构材料及其制备方法,其采用多层淋膜复合机在三层针刺无纺布中通过淋膜形成两层HDPE薄膜,构成多层复合中空夹芯结构,其中由于三层针刺无纺布均保留了针刺无纺布的多孔结构,能够起到减震吸音作用,而两层HDPE薄膜具有蒸汽渗透性差的特性,能够隔水阻油,可替代目前现有技术中仅使用纯针刺无纺布材料;此外还可根据使用环境不同在该结构上层增设阻燃层和耐磨层,在下层增设防滑层,来提高该复合材料阻燃性、耐磨性和防滑性,使该复合材料的使用范围和使用环境更加广泛,特别适合于制作汽车地毯、车用内外轮罩护板等;本发明所述制备方法无污染,对环境友好,所使用设备均为常规设备,生产简便易操作,容易推广使用。
Description
技术领域
本发明涉及一种多层复合材料及其制备方法,尤其涉及一种多层复合中空夹芯结构材料及其制备方法,属于多层复合高分子材料及其加工技术领域。
背景技术
随着经济的快速发展以及人们生活水平的不断提高,汽车工业得到迅速发展,人们对汽车的要求不再仅仅是汽车本身的质量、功能及外观造型的优美,而对汽车内部装饰的要求也越来越高。车用地毯大多采用针刺地毯,其是以棉、、麻、毛、丝、草等天然纤维或化学合成纤维类原料经手工或机械工艺进行针刺而成的地面铺敷物。
车用地毯及外轮罩能够起到吸收噪音、抗振减振的功能,从而可让汽车在行驶过程中吸音降噪,将汽车运动所产生噪声对周围环境及乘客的影响降低。现有技术中汽车的外轮罩通常采用塑料注塑或吸塑制得,而随着车用地毯的运用越来越广泛,其不仅用于汽车驾驶室、行李箱等地方,汽车外轮罩也可以采用针刺地毯经热毡冷压制成。
针刺工艺制得的热熔毡,其主要成分是PET/PP纤维,经加热模压后制成外轮罩产品,这类外轮罩产品的优点是成本低、质量轻、吸音减振效果佳,但因其为多孔结构,使用过程中防水和防油效果差,尤其是在高纬度极端气候条件下,因多孔结构容易吸水及处于低温环境下的原因,使得外轮罩非常容易形成一个冰坨,使其本身具有的吸音、减震、隔音功能丧失殆尽。为满足人们汽车外轮罩在不同气候条件下均能正常使用,有必要研发出一种不仅具有吸音减振功能,还具有防水防油功能的多层复合中空夹芯结构材料。
发明内容
为解决上述技术问题,本发明提供了一种多层复合中空夹芯结构材料及其制备方法,由该方法制备而成的多层复合中空夹芯结构材料在具有吸音减振功能基础上还能够防水防油。
本发明的技术方案是:
本发明公开了一种多层复合中空夹芯结构材料,该多层复合中空夹芯结构材料包括由自底层向顶层依次层叠设置的第一针刺无纺布层、第一HDPE淋膜层、第二针刺无纺布层、第二HDPE淋膜层和第三针刺无纺布层组合制备而成。
其中所述第一、二和三针刺无纺布层均为由40-60%的PP纤维和40-60%的PET纤维混合后经针刺形成的无纺布层。所述第一针刺无纺布层的重量为40-50g/m2,且该第一针刺无纺布层所使用的PP纤维和PET纤维的细度均为8-10旦;所述第二针刺无纺布层的重量为120-150g/m2,且该第二针刺无纺布层所使用的PP纤维和PET纤维的细度均为15-20旦;所述第三针刺无纺布层的重量为150-200g/m2,且该第三针刺无纺布层所使用的PP纤维和PET纤维的细度均为12-14旦。
其中所述第一、二HDPE淋膜层均为以高密度聚乙烯为主要原料喷淋形成的HDPE淋膜层。所述第一HDPE淋膜层为以质量百分比为95-96%且密度为0.95-0.96g/cm3的高密度聚乙烯和质量百分比为4-5%且密度为0.93-0.94g/cm3的线性低密度聚乙烯为原料喷淋形成的淋膜层,该第一HDPE淋膜层的厚度为0.3-0.5mm。所述第二HDPE淋膜层为以质量百分比为84-90%且密度为0.95-0.96g/cm3的高密度聚乙烯、质量百分比为7-12%且密度为0.91-0.92g/cm3的线性低密度聚乙烯和质量百分比为1-2%的轻质碳酸钙为原料喷淋而成的淋膜层,该第二HDPE淋膜层的厚度为0.3-0.5mm。
为增强本发明所述多层复合中空夹芯结构材料的阻燃、耐磨及防滑性能,其还可以在第三针刺无纺布层的上表面还层叠设有一厚度为0.1-0.2mm的阻燃层,并在阻燃层的上表面层叠设有一厚度为0.1-0.2mm的耐磨层,该耐磨层上设有耐磨纹路,并在第一针刺无纺布层的下表面还层叠设有一厚度为0.2-0.4mm的防滑层。其中所述阻燃层由包括铝镁水滑石胶体10-15重量份和助留剂CPAM0.03-0.5重量份的组分经涂布制备而成;所述耐磨层由聚丙烯树脂制备而成;所述防滑层由包括丙烯酸树脂50-60重量份、SEBS树脂45-60重量份、乙烯基三甲氧基硅烷0.5-1.5重量份、白油2.5-4.0重量份和硬脂酸0.1-1.0重量份的组分制备而成。
本发明还公开了一种上述多层复合中空夹芯结构材料的制备方法,该制备方法包括下述步骤:
(1)将PP纤维和PET纤维按照第一、二和三针刺无纺布层所使用纤维细度的使用要求分别进行配料,然后依次经初步混合、开松、二次混合、梳理机疏平、铺成多层纤维网、针刺后,分别得到第一、二和三针刺无纺布层;
(2)采用多层淋膜复合机,在上述制备得到的第一针刺无纺布和第二针刺无纺布层之间淋膜得到第一HDPE淋膜层,在第二针刺无纺布层和第三针刺无纺布层之间淋膜得到第二HDPE淋膜层,经多层淋膜复合机复合后得到多层复合中空夹芯结构材料。
更进一步的,如所述多层复合中空夹芯结构材料还包括阻燃层、耐磨层和防滑层,则还包括下述步骤:
(3)将防滑层用各组分按照配方用量进行配料并混合均匀后,熔融得到防滑层共混物,将该熔融状态的防滑层共混物注射到上胶机的储胶槽内,然后采用该上胶机在步骤(2)中所得复合材料的第一针刺无纺布层的背面进行涂胶后形成防滑层;
(4)将阻燃层用各组分按照配方用量进行配料并混合均匀得到阻燃层共混物,然后采用涂布方式将阻燃层共混物涂布到步骤(2)中所得复合材料的第三针刺无纺布层的正面,并通过烘干机在140-150℃下烘15-20min至烘干;
(5)将耐磨层用丙烯酸树脂与步骤(4)中复合材料阻燃层的正面通过热烫复合机层叠复合在一起,热烫复合温度为170-180℃,得到多层复合中空夹芯结构材料。
本发明的有益技术效果是:本发明采用多层淋膜复合机在三层针刺无纺布中通过淋膜方式形成两层HDPE薄膜,构成多层复合中空夹芯结构,其中由于三层针刺无纺布均保留了针刺无纺布的多孔结构,能够起到减震吸音作用,而两层HDPE薄膜具有蒸汽渗透性差的特性,能够隔水阻油,可替代目前现有技术中仅使用纯针刺无纺布材料;此外还可以根据使用环境的不同在该结构的上层增设阻燃层和耐磨层,在下层增设防滑层,来提高该复合材料的阻燃性、耐磨性和防滑性能,使该复合材料的使用范围和使用环境更加广泛,特别适合于制作汽车地毯、车用内外轮罩护板等;本发明所述制备方法无污染,对环境友好,所使用设备均为常规设备,生产简便易操作,容易推广使用。
附图说明
图1是本发明所述多层复合中空夹芯结构材料的结构示意图之一;
图2是本发明所述多层复合中空夹芯结构材料的结构示意图之二;
其中:
1-第一针刺无纺布层;2-第一HDPE淋膜层;3-第二针刺无纺布层;4-第二HDPE淋膜层;5-第三针刺无纺布层;6-阻燃层;7-耐磨层;8-防滑层。
具体实施方式
为了能够更清楚了解本发明的技术手段,并可依照说明书的内容予以实施,下面结合附图和实施例,对本发明的具体实施方式作进一步详细描述,以下实施例用于说明本发明,但不用来限制本发明的范围。
具体实施例1(不含阻燃层、耐磨层和防滑层)
第三针刺无纺布层:60wt.%PP纤维(12旦),40wt.%PET纤维(12旦),重量60g/cm3;
第二HDPE淋膜层:90wt.%高密度聚乙烯(密度0.96g/cm3)、9wt.%线性低密度聚乙烯(密度0.91g/cm3)和1wt.%轻质碳酸钙,厚度0.12mm;
第二针刺无纺布层:50wt.%PP纤维(20旦),50wt.%PET纤维(15旦),重量80g/cm3;
第一HDPE淋膜层:96wt.%高密度聚乙烯(密度0.95g/cm3)和4wt.%线性低密度聚乙烯(密度0.93g/cm3),厚度0.06mm;
第一针刺无纺布层:40wt.%PP纤维(8旦),60wt.%PET纤维(10旦),重量45g/cm3。
制备方法:
(1)将上述PP纤维和PET纤维按照第一、二和三针刺无纺布层所使用纤维细度的使用要求分别进行配料,然后依次经初步混合、开松、二次混合、梳理机疏平、铺成多层纤维网、针刺后,分别得到第一、二和三针刺无纺布层;
(2)采用多层淋膜复合机,在上述制备得到的第一针刺无纺布和第二针刺无纺布层之间淋膜得到第一HDPE淋膜层,在第二针刺无纺布层和第三针刺无纺布层之间淋膜得到第二HDPE淋膜层,经多层淋膜复合机复合后得到多层复合中空夹芯结构材料A。
具体实施例2(含阻燃层、耐磨层和防滑层)
耐磨层:聚丙烯树脂,厚度为0.1mm;
阻燃层:铝镁水滑石胶体10重量份、助留剂CPAM0.03重量份、海泡石2.0重量份,其中铝镁水滑石胶体的制备为现有技术,本申请中不再赘述,阻燃层厚度为0.1mm;
第三针刺无纺布层:45wt.%PP纤维(13旦),55wt.%PET纤维(14旦),重量55g/cm3;
第二HDPE淋膜层:88wt.%高密度聚乙烯(密度0.95g/cm3)、10wt.%线性低密度聚乙烯(密度0.92g/cm3)和2wt.%轻质碳酸钙,厚度0.15mm;
第二针刺无纺布层:60wt.%PP纤维(18旦),40wt.%PET纤维(20旦),重量100g/cm3;
第一HDPE淋膜层:95wt.%高密度聚乙烯(密度0.96g/cm3)和5wt.%线性低密度聚乙烯(密度0.94g/cm3),厚度0.10mm;
第一针刺无纺布层:60wt.%PP纤维(10旦),40wt.%PET纤维(8旦),重量40g/cm3;
防滑层:丙烯酸树脂50重量份、SEBS树脂50重量份、乙烯基三甲氧基硅烷0.5重量份、白油2.5重量份和硬脂酸0.2重量份,厚度为0.2mm。
制备方法:
(1)将PP纤维和PET纤维按照第一、二和三针刺无纺布层所使用纤维细度的使用要求分别进行配料,然后依次经初步混合、开松、二次混合、梳理机疏平、铺成多层纤维网、针刺后,分别得到第一、二和三针刺无纺布层;
(2)采用多层淋膜复合机,在上述制备得到的第一针刺无纺布和第二针刺无纺布层之间淋膜得到第一HDPE淋膜层,在第二针刺无纺布层和第三针刺无纺布层之间淋膜得到第二HDPE淋膜层,经多层淋膜复合机复合后得到复合材料;
(3)将防滑层用各组分按照配方用量进行配料并混合均匀后,熔融得到防滑层共混物,将该熔融状态的防滑层共混物注射到上胶机的储胶槽内,然后采用该上胶机在步骤(2)中所得复合材料的第一针刺无纺布层的背面进行涂胶后形成防滑层;
(4)将阻燃层用各组分按照配方用量进行配料并混合均匀得到阻燃层共混物,然后采用涂布方式将阻燃层共混物涂布到步骤(2)中所得复合材料的第三针刺无纺布层的正面,并通过烘干机在140℃下烘20min至烘干;
(5)将耐磨层用丙烯酸树脂与步骤(4)中复合材料阻燃层的正面通过热烫复合机层叠复合在一起,热烫复合温度为170℃,得到多层复合中空夹芯结构材料B。
上述制备得到的多层复合中空夹芯结构材料A和B均可以采用模压成型的方式用于生产汽车外轮罩。本发明采用多层淋膜复合机在三层针刺无纺布中通过淋膜方式形成两层HDPE薄膜,构成多层复合中空夹芯结构,其中由于三层针刺无纺布均保留了针刺无纺布的多孔结构,能够起到减震吸音作用,而两层HDPE薄膜具有蒸汽渗透性差的特性,能够隔水阻油,可替代目前现有技术中仅使用纯针刺无纺布材料;此外还可以根据使用环境的不同在该结构的上层增设阻燃层和耐磨层,在下层增设防滑层,来提高该复合材料的阻燃性、耐磨性和防滑性能,使该复合材料的使用范围和使用环境更加广泛,特别适合于制作汽车地毯、车用内外轮罩护板等;本发明所述制备方法无污染,对环境友好,所使用设备均为常规设备,生产简便易操作,容易推广使用。
以上所述仅是本发明的优选实施方式,并不用于限制本发明,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明技术原理的前提下,还可以做出若干改进和变型,这些改进和变型也应视为本发明的保护范围。
Claims (10)
1.一种多层复合中空夹芯结构材料,其特征在于:包括由自底层向顶层依次层叠设置的第一针刺无纺布层(1)、第一HDPE淋膜层(2)、第二针刺无纺布层(3)、第二HDPE淋膜层(4)和第三针刺无纺布层(5)组合制备而成,其中所述第一、二和三针刺无纺布层均为由40-60%的PP纤维和40-60%的PET纤维混合后经针刺形成的无纺布层;所述第一、二HDPE淋膜层均为以高密度聚乙烯为主要原料喷淋形成的HDPE淋膜层。
2.根据权利要求1所述的多层复合中空夹芯结构材料,其特征在于:所述第一针刺无纺布层的重量为120-150g/m2,且该第一针刺无纺布层所使用的PP纤维和PET纤维的细度均为8-10旦;所述第二针刺无纺布层的重量为150-200g/m2,且该第二针刺无纺布层所使用的PP纤维和PET纤维的细度均为15-20旦;所述第三针刺无纺布层的重量为150-250g/m2,且该第三针刺无纺布层所使用的PP纤维和PET纤维的细度均为12-14旦。
3.根据权利要求1所述的多层复合中空夹芯结构材料,其特征在于:所述第一HDPE淋膜层为以质量百分比为95-96%且密度为0.95-0.96g/cm3的高密度聚乙烯和质量百分比为4-5%且密度为0.93-0.94g/cm3的线性低密度聚乙烯为原料喷淋形成的淋膜层,该第一HDPE淋膜层的厚度为0.3-0.5mm。
4.根据权利要求1所述的多层复合中空夹芯结构材料,其特征在于:所述第二HDPE淋膜层为以质量百分比为84-90%且密度为0.95-0.96g/cm3的高密度聚乙烯、质量百分比为7-12%且密度为0.91-0.92g/cm3的线性低密度聚乙烯和质量百分比为1-2%的轻质碳酸钙为原料喷淋而成的淋膜层,该第二HDPE淋膜层的厚度为0.3-0.6mm。
5.根据权利要求1所述的多层复合中空夹芯结构材料,其特征在于:所述第三针刺无纺布层(5)的上表面还层叠设有一厚度为0.1-0.2mm的阻燃层(6),所述阻燃层(6)的上表现还层叠设有一厚度为0.1-0.2mm的耐磨层(7)。
6.根据权利要求5所述的多层复合中空夹芯结构材料,其特征在于:所述阻燃层(6)由包括铝镁水滑石胶体10-15重量份和助留剂CPAM0.03-0.5重量份的组分经涂布制备而成;所述耐磨层(7)由聚丙烯树脂制备而成。
7.根据权利要求1所述的多层复合中空夹芯结构材料,其特征在于:所述第一针刺无纺布层(1)的下表面还层叠设有一厚度为0.2-0.4mm的防滑层(8)。
8.根据权利要求7所述的多层复合中空夹芯结构材料,其特征在于:所述防滑层(8)由包括丙烯酸树脂50-60重量份、SEBS树脂45-60重量份、乙烯基三甲氧基硅烷0.5-1.5重量份、白油2.5-4.0重量份和硬脂酸0.1-1.0重量份的组分制备而成。
9.一种权利要求1至8中任一权利要求所述多层复合中空夹芯结构材料的制备方法,其特征在于:包括下述步骤:
(1)将PP纤维和PET纤维按照第一、二和三针刺无纺布层所使用纤维细度的使用要求分别进行配料,然后依次经初步混合、开松、二次混合、梳理机疏平、铺成多层纤维网、针刺后,分别得到第一、二和三针刺无纺布层;
(2)采用多层淋膜复合机,在上述制备得到的第一针刺无纺布和第二针刺无纺布层之间淋膜得到第一HDPE淋膜层,在第二针刺无纺布层和第三针刺无纺布层之间淋膜得到第二HDPE淋膜层,经多层淋膜复合机复合后得到多层复合中空夹芯结构材料。
10.根据权利要求9所述的多层复合中空夹芯结构材料的制备方法,其特征在于:还包括下述步骤:
(3)将防滑层用各组分按照配方用量进行配料并混合均匀后,熔融得到防滑层共混物,将该熔融状态的防滑层共混物注射到上胶机的储胶槽内,然后采用该上胶机在步骤(2)中所得复合材料的第一针刺无纺布层的背面进行涂胶后形成防滑层;
(4)将阻燃层用各组分按照配方用量进行配料并混合均匀得到阻燃层共混物,然后采用涂布方式将阻燃层共混物涂布到步骤(2)中所得复合材料的第三针刺无纺布层的正面,并通过烘干机在140-150℃下烘15-20min至烘干;
(5)将耐磨层用丙烯酸树脂与步骤(4)中复合材料阻燃层的正面通过热烫复合机层叠复合在一起,热烫复合温度为170-180℃,得到多层复合中空夹芯结构材料。
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